Silicone-Free Phosphor Wheel for High-Temperature Laser Projectors

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Solution Overview

Problem

Conventional laser projectors using phosphor wheels with silicone suffer from high-temperature degradation, leading to reduced light-emitting efficiency and short service life due to silicone's inability to withstand high temperatures.

Innovation Solution

A wavelength conversion and filtering module with a phosphor wavelength conversion unit not encapsulated by or mixed with silicone, utilizing a reflection unit, prism sheet, and filter unit, where the phosphor is sintered, coated, or deposited, and the module's optical regions can move to insert into the beam path, ensuring efficient light conversion and filtering without silicone, thus preventing thermal damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If phosphor is mixed with silicone and coated onto substrate to construct phosphor wheel, then ease of manufacture is improved, but reliability deteriorates due to silicone degradation at high temperature

Engineering Contradiction:

Improveease of manufactureVSAvoidreliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent extracts and removes silicone from the phosphor wheel structure, replacing it with a silicone-free phosphor layer directly coated on a reflective substrate. This eliminates the harmful silicone component while maintaining the phosphor wheel's functional integrity for wavelength conversion.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs composite material structures including reflective substrate combined with phosphor materials (such as yellow phosphor, green phosphor, red phosphor) to create a high-temperature-resistant phosphor wheel that achieves both manufacturability and reliability without silicone.

Inventive Principle:

Principle #40Composite materials

2Illumination intensity

If laser beam excites phosphor with silicone for long period, then light emission function is achieved, but temperature increases causing silicone degradation and reduced light-emitting efficiency

Engineering Contradiction:

Improvelight-emitting efficiencyVSAvoidtemperature

Core Design Contradiction:

Illumination intensityVSTemperature

Solution Approach 1:

The patent converts the harmful high-temperature effect that degrades silicone into a beneficial demonstration of the silicone-free design's thermal stability. By removing silicone, the system can withstand high temperatures from continuous laser excitation, maintaining light-emitting efficiency over extended operation periods.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent changes the material parameter from silicone-containing phosphor to silicone-free phosphor, fundamentally altering the thermal resistance parameter of the phosphor wheel to withstand high-temperature operation without degradation.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If silicone is used in phosphor wheel, then ease of coating and manufacturing is improved, but service life decreases due to thermal damage to silicone

Engineering Contradiction:

Improveease of coatingVSAvoidservice life

Core Design Contradiction:

Ease of manufactureVSDuration of action of stationary object

Solution Approach 1:

The patent replaces the short-lived silicone-based phosphor coating with a durable silicone-free phosphor layer that can withstand high temperatures, effectively creating a long-lasting phosphor wheel that maintains its service life under continuous laser excitation.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution achieves favorable light utilization efficiency, reliable light-emitting spectrum, and extended service life by preventing phosphor degradation from high temperatures, ensuring pure color light output and improved projector performance.

Implementation Method 1

the laser light source not only can excite the phosphor to emit light

Methodology Applied

Scientific EffectPhosphor excitation and light emission: Photoluminescence

Implementation Method 2

a reflection unit, a wavelength conversion unit, a prism sheet, and a filter unit

Methodology Applied

Scientific EffectLight reflection: Reflection

Implementation Method 3

a prism sheet, and a filter unit. The wavelength conversion unit is located between the reflection unit and the prism sheet

Methodology Applied

Scientific EffectLight refraction and dispersion: Refraction

Implementation Method 4

a filter unit. The wavelength conversion unit is located between the reflection unit and the prism sheet

Methodology Applied

Scientific EffectOptical filtering: Filter (optical)

Data Source

PatentEP2869109B1Wavelenght conversion and filtering module and light source system

Publication Date: 2016.12.28 CORETRONIC CORPORATION

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AI summary

A wavelength conversion and filtering module that includes a plurality of optical regions is provided. The optical regions are adapted to move, and at least one of the optical regions includes a reflection unit, a wavelength conversion unit, a prism sheet, and a filter unit. The wavelength conversion unit is located between the reflection unit and the prism sheet. The prism sheet is located between the wavelength conversion unit and the filter unit. A light source system is also provided.